Non-vertical corrugated fins in a heat exchanger and method of manufacturing the same

ABSTRACT

An inclined heat exchanger for use in a motor vehicle. The heat exchanger contains at least two flat tubes and at least two corrugated fins. The flat tubes and the corrugated fins are stacked alternately one above the other in a height direction (HR) to form a stack. The corrugated fins include a rhombic cross-section. A corrugated fin is also provided for use in the heat exchanger, as well as a method for manufacturing the corrugated fin.

FIELD

This disclosure relates generally to a heat exchanger for a motorvehicle. More specifically, this disclosure relates to non-verticalcorrugated fins incorporated into a heat exchanger and a method ofmanufacturing the same.

BACKGROUND

The statements in this section merely provide background informationrelated to the present disclosure and may not constitute prior art.

In modern motor vehicles, the space available for mounting a heatexchanger is often reduced in comparison to the space occupied by a heatexchanger mounted in an older vehicle model. This creates a problem thatcan be solved by the heat exchanger either being constructed withsmaller dimensions or configured to be mounted at an angle. However, inboth of these solutions, the amount of air that flows through the heatexchanger may be significantly reduced and not provide the desiredperformance. It is therefore desirable to provide a heat exchanger thatmay be mounted in a restricted space and maintain the degree of air flowthat supports the required level of performance.

SUMMARY

The present disclosure generally provides a heat exchanger for use in amotor vehicle. This heat exchanger generally comprises at least two flattubes through which a liquid flows in a width direction (BR), and atleast two corrugated fins through which air flows in a depth direction(TR). The corrugated fins comprise a rhombic cross-section in a planespanned transversely to the width direction (BR). The flat tubes and thecorrugated fins are stacked one on top of the other alternately in aheight direction (HR) to form a stack. The height direction (HR), thewidth direction (BR) and the depth direction (TR) are orientedperpendicular to each other.

According to another aspect of the present disclosure, the cross-sectionof the corrugated fins may comprise, in a plane spanned transversely tothe width direction (BR), two edges aligned parallel to the depthdirection (TR) and two edges aligned at an inclination angle (NW) to theheight direction (HR). This inclination angle (NW) may be between 5° and85°; alternatively, between 25° and 65°; alternatively, about 30° orabout 60°.

According to yet another aspect of the present disclosure, the flattubes separated by the corrugated fins overlap only in regions in thedepth direction (TR) and completely in the width direction (BR). Thecorrugated fins and the flat tubes adjacent thereto overlap only inregions in the depth direction (TR) and completely in the widthdirection (BR). The flat tubes and the corrugated fins in the stack maybe displaced one above the other in the depth direction (TR) in such away that a height center axis (HMA) passing through the center of thestack is aligned with the height direction (HR) at an inclination angle(NW) that is greater than zero.

According to another aspect of the present disclosure, a corrugated finfor use in the heat exchanger described above and further defined hereinis provided. This corrugated fin generally comprises a single piece ofmaterial with a plurality of folds extending in the depth direction (TR)and adjacent to each other in the width direction (BR), and a rhombiccross-section in a plane spanned transversely to the width direction(BR).

According to yet another aspect of the present disclosure, a method ofmanufacturing the corrugated fin for use in the heat exchanger isprovided. This method generally comprises folding a single piece ofmaterial, such that the corrugated fin contains a rectangularcross-section in a plane spanned transversely to the width direction(BR), and cutting the single piece of material, such that the corrugatedfin contains a rhombic cross-section in the plane spanned transverselyto the width direction (BR). The material may be cut to form thecorrugated fin in such a way that a cross-section of the corrugated finin a plane spanned transversely to the width direction (BR) contains twoedges aligned parallel to the depth direction (TR) and two edges alignedat an inclination angle (NW) to the height direction (HR). The materialmay be cut to form the corrugated fin on both sides at an angle thatcorresponds to an extension of the individual folds.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

DRAWINGS

In order that the disclosure may be well understood, there will now bedescribed various forms thereof, given by way of example, referencebeing made to the accompanying drawings, in which each drawing isprovided as a schematic representation.

FIG. 1 is a partial sectional view of a heat exchanger formed accordingto the teachings of the present disclosure.

FIG. 2 depicts a corrugated fin before the step of folding in themanufacturing process according to the teachings of the presentdisclosure.

FIG. 3 depicts the corrugated fin of FIG. 2 after the step of folding inthe manufacturing process of the present disclosure.

FIG. 4 depicts the corrugated fin of FIG. 3 after the step of cutting inthe manufacturing process of the present disclosure.

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.Various embodiments of the present disclosure are shown in the drawingsand will be explained in more detail in the following description,wherein like reference signs refer to like or similar or functionallyidentical components or features.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is in no wayintended to limit the present disclosure or its application or uses. Forexample, the heat exchanger made and used according to the teachingscontained herein are described throughout the present disclosure inconjunction with a motor vehicle. The incorporation and use of such aheat exchanger in other heating, ventilation, air conditioning, andrefrigeration applications wherein the space for mounting the heatexchanger is limited and the design set forther herein would bedesirable is contemplated not to exceed the scope of the presentdisclosure.

For the purpose of this disclosure, the terms “at least one” and “one ormore of” an element are used interchangeably and may have the samemeaning. These terms, which refer to the inclusion of a single elementor a plurality of the elements, may also be represented by the suffix“(s)” at the end of the element. For example, “at least one fin”, “oneor more fins”, and “fin(s)” may be used interchangeably and are intendedto have the same meaning.

Although specific terminology is used herein to describe particularembodiments within the disclosure, this terminology is not intended tolimit any portion of the disclosure. For example, as used herein,singular forms of “a”, “an”, and “the” are intended to include variousplural forms as well, unless the context of their use clearly indicatesotherwise. Terms, such as “comprises”, “includes”, “comprising” or“including” are meant to specify the presence of stated features,integers, steps, operations, elements, and/or components, but are notmeant to preclude the presence and/or addition of one or more otherfeatures, integers, steps, operations, elements, components, and/orgroups associated therewith.

The present disclosure addresses the deficiency of the prior art byproviding a design for an inclined heat exchanger having a corrugatedfin that provides an improvement over or at least an alternativeembodiment for a heat exchanger of the generic type, in which thedescribed disadvantages are overcome. The present disclosure alsoprovides a method for manufacturing the corrugated fin incorporated intothe heat exchanger.

The heat exchanger according to the present disclosure may be providedfor a motor vehicle. The heat exchanger contains at least two flat tubesthrough which a liquid can flow in a width direction and at least twocorrugated fins through which air can flow in a depth direction. Theflat tubes and the corrugated fins are stacked alternately one above theother in a height direction to form a stack. The height direction, thewidth direction and the depth direction are thereby alignedperpendicularly to one another. According to one aspect of the presentdisclosure, the respective corrugated fin contains a rhombiccross-section in a plane spanned transversely to the width direction.

The respective flat tube rests on a contact surface of the respectiveadjacent corrugated fin and is connected to the respective corrugatedfin by a material bond. The two opposing contact surfaces of therespective corrugated fin are aligned transversely to the heightdirection. Due to the rhombic cross-section of the respective corrugatedfin, the two opposing contact surfaces of the corrugated fin aredisplaced relative to one another transversely to the height directionin the depth direction, so that the adjacent flat tubes abutting therespective corrugated fin on both sides are displaced relative to oneanother transversely to the height direction in the depth direction. Asa result, the stack of the heat exchanger deviates in its shape from acuboid and is formed to be inclined transversely to the height directionin the depth direction. The respective corrugated fin is further alignedtransversely to the height direction. Accordingly, the air flow in theheat exchanger is not negatively affected despite the inclined shape ofthe stack.

In a plane spanned transversely to the width direction, thecross-section of the respective corrugated fin may contain two edgesaligned parallel to the depth direction and two edges aligned at aninclination angle to the height direction. In other words, therespective corrugated fin may be formed inclined to the heightdirection. The flat tubes and the corrugated fins in the stack may bedisplaced one above the other in the depth direction such that a centralheight axis of the stack passing through the center of the stack isoriented at the inclination angle greater than zero to the heightdirection. The inclination angle may be between 5° and 85°,alternatively, between 25° and 65°, alternatively, at either about 30°or about 60°. The inclination angle may be adapted to the desiredinclination of the heat exchanger and/or to the available installationspace in the motor vehicle.

Advantageously, the respective adjacent flat tubes may overlap eachother only in regions in the depth direction and completely in the widthdirection. In other words, the respective flat tubes may be arrangeddisplaced to each other transversely to the height direction. Moreover,the respective corrugated fin and the respective adjacent flat tube mayoverlap each other only in regions in the depth direction and completelyin the width direction. In other words, the respective flat tube and therespective corrugated fin may be arranged displaced to each othertransversely to the height direction.

The present disclosure also relates to a corrugated fin for use in theheat exchanger described above. The corrugated fin is folded from asingle piece of material and contains a plurality of folds extending inthe depth direction and adjacent to each other in the width direction.The corrugated fin contains a rhombic cross-section in a plane spannedtransversely to the width direction. In order to avoid repetition,reference is made at this point to the above explanations.

The present disclosure also relates to a method of manufacturing thecorrugated fin described above. The corrugated fin is folded from asingle piece of material in such a way that the corrugated fin containsa rectangular cross-section in a plane spanned transversely to the widthdirection. Thereafter, the folded material is cut on both sides suchthat the corrugated fin contains a rhombic cross-section in the planespanned transversely to the width direction. In other words, the rhombiccross-section of the corrugated fin is produced only after folding,which simplifies the production of the corrugated fin.

The corrugated fin can be cut off from the material on both sides insuch a way that a cross-section of the corrugated fin in a plane spannedtransversely to the width direction contains two edges aligned parallelto the depth direction and two edges aligned at an inclination angle tothe height direction. Thus, the corrugated fin may be formed inclined tothe height direction. In this case, the corrugated fin can be cut onboth sides at an angle to the extension of the individual folds in thecorrugated fin.

Other important features and advantages of the present disclosure willbe apparent hereafter, from the drawings and from the accompanyingfigure description with reference to the drawings. It is understood thatthe above features, and those to be explained below, may be used notonly in the combination indicated in each case, but also in othercombinations or alone, without departing from the scope of the presentinvention.

FIG. 1 shows a sectional view of a heat exchanger 1 according to oneaspect of the present disclosure. In FIG. 1 , only a section of the heatexchanger 1 is shown. Here, the heat exchanger 1 contains a plurality offlat tubes 2 through which a fluid can flow in a width direction (BR)and a plurality of corrugated fins 3 through which air can flow in adepth direction (TR). The flat tubes 2 and the corrugated fins 3 areformed flat and extend transversely to a height direction (HR). The flattubes 2 and the corrugated fins 3 are stacked alternately one above theother in the height direction (HR) to form a stack 4. The heightdirection (HR), the width direction (BR) and the depth direction (TR)are aligned perpendicularly to each other.

According to another aspect of the present disclosure, the respectivecorrugated fin 3 contains a rhombic cross-section transversely to thewidth direction (BR). In particular, the cross-section of the respectivecorrugated fin 3 contains, in a plane spanned transversely to the widthdirection (BR), two edges aligned parallel to the depth direction (TR)and two edges aligned at an inclination angle (NW) - in this case (FIG.1 ) approximately 30° - to the height direction (HR). As a result, therespective corrugated fin 3 is formed inclined to the height direction(HR) and two opposing contact surfaces 3 a and 3 b of the corrugated fin3 are displaced to each other in the depth direction (TR). However, aircan still flow through the corrugated fins 3 in the depth direction(TR).

Still referring to FIG. 1 , since the respective flat tube 2 rests onthe corresponding contact surface 3 a or 3 b of the corrugated fin 3,the mutually adjacent flat tubes 2 are also displaced relative to oneanother in the depth direction (TR). As a result, the heat exchanger 1or the stack 4 has a rhombic cross-section in the plane spannedtransversely to the width direction (BR). Thereby, a height center axis(HMA) of the heat exchanger 1 in the plane spanned transversely to thewidth direction (TR) is oriented at the inclination angle (NW) - hereabout 30° as shown - to the height direction (HR). In this case, thecentral height axis (NMA) is an axis which always passes through thecenter of the stack 4 in a plane spanned transversely to the heightdirection (HR). Advantageously, the heat exchanger 1 can be mountedinclined in a motor vehicle without air flow through the corrugated fins3 being negatively affected.

Referring now to FIG. 2 and FIG. 3 , several views of the corrugated fin3 are shown during the manufacturing process. During manufacture, thecorrugated fin 3 is folded in a process and then cut off. In theprocess, the corrugated fin 3 having a plurality of folds 5 is foldedfrom a single piece of material 6. In FIG. 2 , the corrugated fin 3 isshown not folded and not cut off. In FIG. 3 , the corrugated fin 3 isshown folded and not cut off. The piece of material 6 or corrugated fin3 is shown with solid lines before being cut off, while the broken linesprovide a view of what the corrugated fin 3 looks like after being cutoff. FIG. 4 shows a view of the corrugated fin 3 after cutting. Here,lateral portions of the piece of material 6 or corrugated fin 3 are cutoff so that initially rectangular cross-section becomes rhombic. FIGS.2-4 also show a louver bank region 7 with dotted lines. The single piecematerial 6 may be cut to form the corrugated fin on both sides at anangle that corresponds to an extension of the individual folds. Thisangle may be the same as the inclination angle in the range of 5° to85°; alternatively, between 25° and 65°; alternatively, at about 30° orabout 60°.

Within this specification, embodiments have been described in a waywhich enables a clear and concise specification to be written, but it isintended and will be appreciated that embodiments may be variouslycombined or separated without parting from the invention. For example,it will be appreciated that all preferred features described herein areapplicable to all aspects of the invention described herein.

The foregoing description of various forms of the invention has beenpresented for purposes of illustration and description. It is notintended to be exhaustive or to limit the invention to the precise formsdisclosed. Numerous modifications or variations are possible in light ofthe above teachings. The forms discussed were chosen and described toprovide the best illustration of the principles of the invention and itspractical application to thereby enable one of ordinary skill in the artto utilize the invention in various forms and with various modificationsas are suited to the particular use contemplated. All such modificationsand variations are within the scope of the invention as determined bythe appended claims when interpreted in accordance with the breadth towhich they are fairly, legally, and equitably entitled.

What is claimed is:
 1. A heat exchanger for use in a motor vehicle, theheat exchanger comprising: at least two flat tubes through which aliquid flows in a width direction (BR), and at least two corrugated finsthrough which air flows in a depth direction (TR), the corrugated finscomprising a rhombic cross-section in a plane spanned transversely tothe width direction (BR), wherein the flat tubes and the corrugated finsare stacked one on top of the other alternately in a height direction(HR) to form a stack, wherein the height direction (HR), the widthdirection (BR) and the depth direction (TR) are oriented perpendicularto each other.
 2. The heat exchanger according to claim 1, wherein thecross-section of the corrugated fins comprise, in a plane spannedtransversely to the width direction (BR), two edges aligned parallel tothe depth direction (TR) and two edges aligned at an inclination angle(NW) to the height direction (HR).
 3. The heat exchanger according toclaim 2, wherein the inclination angle (NW) is between 5° and 85°. 4.The heat exchanger according to claim 3, wherein the inclination angle(NW) is between 25° and 65°.
 5. The heat exchanger according to claim 4,wherein the inclination angle (NW) is about 30° or about 60°.
 6. Theheat exchanger according to claim 1, wherein the flat tubes separated bythe corrugated fins overlap only in regions in the depth direction (TR)and completely in the width direction (BR).
 7. The heat exchangeraccording to claim 1, wherein the corrugated fins and the flat tubesadjacent thereto overlap only in regions in the depth direction (TR) andcompletely in the width direction (BR).
 8. The heat exchanger accordingto claim 1, wherein the flat tubes and the corrugated fins in the stackare displaced one above the other in the depth direction (TR) in such away that a height center axis (HMA) passing through the center of thestack is aligned with the height direction (HR) at an inclination angle(NW) greater than zero.
 9. A corrugated fin for use in the heatexchanger according to claim 1, the corrugated fin comprising: a singlepiece of material with a plurality of folds extending in the depthdirection (TR) and adjacent to each other in the width direction (BR),and a rhombic cross-section in a plane spanned transversely to the widthdirection (BR).
 10. A method of manufacturing the corrugated finaccording to claim 9, the method comprising: folding a single piece ofmaterial, such that the corrugated fin contains a rectangularcross-section in a plane spanned transversely to the width direction(BR), and cutting the single piece of material, such that the corrugatedfin contains a rhombic cross-section in the plane spanned transverselyto the width direction (BR).
 11. The method according to claim 10,wherein the material is cut to form the corrugated fin in such a waythat a cross section of the corrugated fin in a plane spannedtransversely to the width direction (BR) contains two edges alignedparallel to the depth direction (TR) and two edges aligned at aninclination angle (NW) to the height direction (HR).
 12. The methodaccording to claim 10, wherein the material is cut to form thecorrugated fin on both sides at an angle that corresponds to anextension of the individual folds.
 13. The method according to claim 11,wherein the material is cut to form the corrugated fin on both sides atan angle that corresponds to an extension of the individual folds. 14.The method according to claim 12, wherein the angle is between 5° and85°.
 15. The method according to claim 13, wherein the angle is between25° and 65°.
 16. The method according to claim 12, wherein the angle isabout 30° or about 60°.